Electrosurgical forceps

ABSTRACT

An electrosurgical forceps includes first and second shaft members pivotably coupled to one another via a pivot member such that pivoting of the first and second shaft members between spaced-apart and approximated positions pivots jaw members thereof between open and closed positions. A knife is translatable between retracted and extended positions. The knife has a stop to prevent distal movement of the knife beyond the extended position.

BACKGROUND

The present disclosure relates to electrosurgical instruments and, moreparticularly, to electrosurgical forceps for grasping, treating, and/ordividing tissue.

TECHNICAL FIELD

A surgical forceps is a plier-like instrument which relies on mechanicalaction between its jaws to grasp tissue. Electrosurgical forceps utilizeboth mechanical clamping action and electrical energy to treat tissue,e.g., coagulate, cauterize, and/or seal tissue.

Typically, once tissue is treated, the surgeon has to accurately severthe treated tissue. Accordingly, many electrosurgical forceps have beendesigned which incorporate a knife configured to effectively severtissue after the tissue is treated.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a surgeon, while the term “proximal”refers to the portion that is being described which is closer to asurgeon. Further, to the extent consistent, any of the aspects describedherein may be used in conjunction with any or all of the other aspectsdescribed herein.

As used herein, the terms parallel and perpendicular are understood toinclude relative configurations that are substantially parallel andsubstantially perpendicular up to about +/−10 degrees from true paralleland true perpendicular.

An electrosurgical forceps provided in accordance with aspects of thepresent disclosure includes a first shaft member, a second shaft memberpivotably coupled to the first shaft member, a first jaw member securedto and extending distally from the first shaft member, a second jawmember secured to and extending distally from the second shaft member,and a knife. The first jaw member includes a jaw frame, an insulativespacer disposed on the jaw frame and defining a longitudinally-extendingchannel, and a tissue-contacting plate disposed on the insulativespacer. The knife is selectively translatable through the first shaftmember from a retracted position to an extended position in which theknife extends at least partially between the first and second jawmembers. The knife includes a distal edge having a sharp, upper segmentand a dull, lower segment depending from the upper segment. The lowersegment is configured to abut the insulative spacer when the knife is inthe extended position.

In aspects, the lower segment of the distal edge of the knife mayprotrude distally beyond the upper segment.

In further aspects, the upper segment of the distal edge of the knifemay extend at an oblique angle relative to a longitudinal axis definedby the knife, and the lower segment may be perpendicular relative to thelongitudinal axis.

In some aspects, the lower segment of the distal edge of the knife maybe received in the channel of the insulative spacer, and the uppersegment may be received in a longitudinally-extending channel defined bythe tissue-contacting plate.

In other aspects, the lower segment of the distal edge of the knife maybe configured to abut an inner peripheral surface of the insulativespacer upon the knife moving to the extended position. The innerperipheral surface of the insulative spacer may define an outerperiphery of the channel.

In another aspect of the present disclosure, an electrosurgical forcepsis provided that includes a first shaft member having a first innerframe, a second shaft member pivotably coupled to the first shaftmember, a first jaw member secured to and extending distally from thefirst shaft member, a second jaw member secured to and extendingdistally from the second shaft member, a knife, and an elongate shellattached to a lateral side of the first inner frame. The knife isselectively translatable through the first shaft member from a retractedposition to an extended position in which the knife extends at leastpartially between the first and second jaw members. The elongate shelldefines a longitudinally-extending passageway configured for slidablereceipt of the knife therethrough.

In aspects, the elongate shell may have an inner surface that definesthe passageway. The inner surface may be configured to permit movementof the knife along a longitudinal axis defined by the knife and resistlateral and vertical movement of the knife relative to the longitudinalaxis.

In further aspects, the elongate shell may be fabricated from plastic.

In other aspects, the knife may have a blade stop protruding outwardlytherefrom configured to abut a proximal edge of the elongate shell whenthe knife moves to the extended position to prevent further distalmovement of the knife along the passageway.

In some aspects, the elongate shell may have a connection tab extendinglaterally therefrom and configured to engage a correspondingly shapedaperture defined in the lateral side of the first inner frame.

In aspects, the elongate shell may have a rectangular shape.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects and features of the present disclosure are describedhereinbelow with reference to the drawings wherein like numeralsdesignate identical or corresponding elements in each of the severalviews:

FIG. 1 is a side, perspective view of an electrosurgical forcepsprovided in accordance with aspects of the present disclosure;

FIG. 2 is a perspective view from one side of the forceps of FIG. 1 withportions of outer housings of first and second shaft members removed toillustrate the internal components therein;

FIG. 3 is a side, perspective view of the forceps of FIG. 1 withportions removed to illustrate a knife within an inner frame of theforceps;

FIG. 4 is a side, perspective view of the inner frame of the first shaftmember separated from a knife guide;

FIG. 5 is a side, cross-sectional view of the knife guide of FIG. 4;

FIG. 6 is a side, perspective view of a jaw member of the forceps;

FIG. 7 is a side, perspective view of the jaw member of FIG. 6 with atissue-contacting plate removed therefrom to reveal an insulativespacer;

FIG. 8 is a side view of the knife of the forceps;

FIG. 9 is a longitudinal cross-sectional view of a distal end of the jawmember of FIG. 6 illustrating the knife in an extended position; and

FIG. 10 is side view of a distal end of another embodiment of the knifeof the forceps.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a forceps 100 provided in accordance withthe present disclosure generally includes first and second shaft members110, 120 and an end effector assembly 200. Shaft members 110, 120 eachhave a proximal end portion 112 a, 122 a and a distal end portion 112 b,122 b. End effector assembly 200 includes first and second jaw members210, 220 extending from distal end portions 112 b, 122 b of shaftmembers 110, 120, respectively. Forceps 100 further includes a pivotmember 130 pivotably coupling first and second shaft members 110, 120with one another, a knife 140 (FIGS. 3 and 8), a knife deploymentmechanism 150 for selectively deploying the knife 140 relative to endeffector assembly 200, a knife lockout 170 for inhibiting deployment ofknife 140 prior to sufficient closure of jaw members 210, 220, and aswitch assembly 180 for enabling the selective supply of electrosurgicalenergy to end effector assembly 100. An electrosurgical cable 300electrically couples forceps 100 to a source of energy (not shown),e.g., an electrosurgical generator, to enable the supply ofelectrosurgical energy to jaw members 210, 220 of end effector assembly200 upon activation of switch assembly 180.

Continuing with reference to FIGS. 1 and 2, each shaft member 110, 120includes an inner frame 114, 124, an outer housing 116, 126 surroundingat least a portion of the respective inner frame 114, 124, and a handle118, 128 engaged with the respective outer housing 116, 126 towardsproximal end portions 112 a, 122 a of shaft members 110, 120,respectively. Outer housings 116, 126 enclose and/or operably supportthe internal components disposed within shaft members 110, 120. Morespecifically, outer housing 116 of shaft member 110 encloses andsupports at least a portion of inner frame 114, knife deploymentmechanism 150, and lockout 170, while outer housing 126 of shaft member120 receives electrosurgical cable 300 and encloses and supports atleast a portion of inner frame 124, switch assembly 180, and the leadwires 310 of electrosurgical cable 300. Handles 118, 128 are engagedwith outer housings 116, 126 towards proximal end portions 112 a, 112 bof shaft members 110, 120 and extend outwardly from shaft members 110,120. Handles 118, 128 define finger holes 119, 129 configured tofacilitate grasping and manipulating shaft members 110, 120.

Referring to FIGS. 3 and 4, inner frame 114 of shaft member 110 includesa body plate 115 a and a reinforcing plate 115 b attached to body plate115 a, e.g., via welding, to provide increased lateral stiffness andstructural support thereto. In embodiments, reinforcing plate 115 b maybe welded to body plate 115 a in at least two places, e.g., towards theproximal and distal end portions thereof. Inner frame 124 of shaftmember 120 and body plate 115 a of inner frame 114 of shaft member 110are pivotably coupled to one another via pivot member 130 such thatshaft members 110, 120 are movable relative to one another betweenspaced-apart and approximated positions to thereby pivot jaw members210, 220 relative to one another between open and closed positions.

Inner frame 114 defines one or more location apertures 115 c, a triggeraperture 115 d, and a longitudinal slot 115 e that each extends throughboth body plate 115 a and reinforcing plate 115 b. The one or morelocation apertures 115 c are configured to receive corresponding posts117 of outer housing 116 to locate and maintain inner frame 114 inposition within outer housing 116. Body plate 115 a extends distallybeyond reinforcing plate 115 b to enable attachment of jaw member 210thereto, e.g., via staking or other suitable engagement. The portion ofbody plate 115 a that extends distally beyond reinforcing plate 115 bfurther defines a pivot aperture 115 f and a pair oflongitudinally-spaced connection apertures 115 h extending transverselytherethrough. Connection apertures 115 h are configured for receipt of apair of correspondingly-shaped tabs 134 of an elongate shell 132 offorceps 100.

With reference to FIGS. 4 and 5, elongate shell 132 of forceps 100 isfabricated from a plastic, such as, for example, a thermoplastic, anelastomer, or any suitable material, and may assume a generallyrectangular cross-sectional profile. In embodiments, elongate shell 132may assume any suitable shape. Elongate shell 132 has an inner surface136 a defining a longitudinally-extending passageway 136 b along thelength thereof. Passageway 136 b is dimensioned for slidable receipt ofknife 140. Passageway 136 b is open at both the proximal and distal endsof elongate shell 132 to permit movement of knife 140 therethrough.Passageway 136 b is sized to permit movement of knife 140 along alongitudinal axis defined by knife 140 while resisting both lateral(e.g., transverse) and vertical (e.g., up and down) movement of knife140 within passageway 136 b. As such, elongate shell 132 guides knife140 along a linear or substantially linear path from the retractedposition to the extended position. Due to the utilization of elongateshell 132, it is not required to form a knife guide slot in inner frame114, which is typically fabricated from metal (e.g., steel). As such,elongate shell 132 eases the manufacturing of inner frame 114.

Elongate shell 132 has a pair of tabs 134 (only one tab is illustrated)extending laterally therefrom. Tabs 134 are configured for receiptwithin the pair of apertures 115 h in the lateral side of body plate 115a of inner frame 114. Tabs 134 may be sized for a friction-fitengagement within apertures 115 h of body plate 115 a. In some aspects,elongate shell 132 may be detachably coupled to lateral side of bodyplate 115 a of inner frame 114. In other aspects, elongate shell 132 maybe assembled to body plate 115 a of inner frame 114 by sliding elongateshell 132 over body plate 115 a of inner frame 114.

Knife 140 has a blade stop 147 (FIG. 3) protruding outwardly therefromconfigured to abut a proximal edge 138 of elongate shell 132 when knife140 moves to the extended position. Upon blade stop 147 of knife 140contacting proximal edge 138 of elongate shell 132, knife 140 isprevented from further advancement. In some aspects, elongate shell 132may have an internal boss or projection (not shown) extending inwardlyfrom the inner surface 136 a thereof into passageway 136 b, such thatblade stop 147 abuts the projection when knife 140 is advanced to theextended position.

With reference to FIGS. 4 and 6-9, jaw member 110 includes a jaw supportor frame 212 (FIG. 4) staked or otherwise engaged, e.g., welded,press-fit, mechanically locked, etc., to portion of body plate 115 athat extends distally beyond reinforcing plate 115 b. Jaw member 210further includes an insulative spacer 213 disposed on jaw support 212,an electrically-conductive, tissue-contacting plate 214 supported oninsulative spacer 213, and an insulative housing 216. Tissue-contactingplate 214 defines a longitudinally-extending knife channel 215 aextending at least partially therethrough and includes one or more stopmembers 215 b disposed thereon and electrically isolated therefrom.Insulative spacer 213 (FIG. 7) also defines a longitudinally-extendingchannel 213 a in alignment with channel 215 a of tissue-contacting plate214. Insulative spacer 213 has an inner peripheral surface 213 b thatdefines an outer periphery of channel 213 a. Insulative housing 216 ofjaw member 210 is overmolded or otherwise secured about a portion of jawsupport 212, insulative spacer 213, tissue-contacting plate 214, andbody plate 115 a of inner frame 114 of shaft member 110.

Referring to FIGS. 8 and 9, knife 140 includes a proximal body 142defining an aperture 144 through which knife 140 is pivotably coupled toa linkage 156 (FIG. 3) of knife deployment mechanism 150 via a pin 163.Knife 140 further includes a distal body 146 defining a lower profile ascompared to proximal body 142 and extending distally from proximal body142. Distal body 146 has a distal edge 148 having a larger profile ascompared to distal body 146. Distal edge 148 has a sharp, upper segment148 a, and a relatively dull, lower segment 148 b extending from a lowerend of upper segment 148 a. Upper segment 148 a of distal edge 148 maybe etched to define an asymmetrically sharpened configuration whereinone lateral side of upper segment 148 a of distal edge 148 extendsfurther distally than the opposite side (due to the removal of materialfrom the opposite side during the etching process). Lower segment 148 bof distal edge 148 of knife 140 is received in channel 213 a ofinsulative spacer 213, and upper segment 148 a of distal edge 148 ofknife 140 is received in channel 215 a of tissue-contacting plate 214.

Lower segment 148 b of distal edge 148 of knife 140 protrudes distallybeyond upper segment 148. As such, lower segment 148 b abuts a distalend of inner peripheral surface 213 b of insulative spacer 213 whenknife 140 is in the extended position. In some aspects, upper and lowersegments 148 a, 148 b of distal edge 148 may be co-terminal. Uppersegment 148 a of distal edge 148 extends at an oblique angle relative tothe longitudinal axis of knife 140, and lower segment 148 b isperpendicular relative to the longitudinal axis of knife 140. In someaspects, upper and lower segments 148 a, 148 b of distal edge 148 mayextend at various angles relative to one another and/or the longitudinalaxis of knife 140.

With reference to FIG. 10, another embodiment of a knife 140′ isillustrated. Knife 140′ varies from knife 140 by having a stop 148 b′that projects distally from a distal end of knife 140′. Knife 140′ has asharp, cutting edge 148 a′ that extends at an oblique angle relative toa longitudinal axis of knife 140′ and which is set back proximally fromstop 148 b′. Stop 148 b′ may be steel, or any suitable material, andhave a cylindrical shape or assume any suitable shape. In use, stop 148b′ abuts a distal end of inner peripheral surface 213 b (FIG. 9) ofinsulative spacer 213 when knife 140′ is in the extended position.

For a detailed description of various components and manners ofoperating forceps 100 of the present disclosure, reference may be madeto U.S. patent application Ser. No. 15/593,672, filed on May 12, 2017,the entire contents of which is incorporated by reference herein.

The various embodiments disclosed herein may also be configured to workwith robotic surgical systems and what is commonly referred to as“Telesurgery.” Such systems employ various robotic elements to assistthe clinician and allow remote operation (or partial remote operation)of surgical instrumentation. Various robotic arms, gears, cams, pulleys,electric and mechanical motors, etc. may be employed for this purposeand may be designed with a robotic surgical system to assist theclinician during the course of an operation or treatment. Such roboticsystems may include remotely steerable systems, automatically flexiblesurgical systems, remotely flexible surgical systems, remotelyarticulating surgical systems, wireless surgical systems, modular orselectively configurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consolesthat are next to the operating theater or located in a remote location.In this instance, one team of clinicians may prep the patient forsurgery and configure the robotic surgical system with one or more ofthe instruments disclosed herein while another clinician (or group ofclinicians) remotely controls the instruments via the robotic surgicalsystem. As can be appreciated, a highly skilled clinician may performmultiple operations in multiple locations without leaving his/her remoteconsole which can be both economically advantageous and a benefit to thepatient or a series of patients.

For a detailed description of exemplary medical work stations and/orcomponents thereof, reference may be made to U.S. Patent ApplicationPublication No. 2012/0116416 (now U.S. Pat. No. 8,828,023), and PCTApplication Publication No. WO2016/025132, the entire contents of eachof which are incorporated by reference herein.

Persons skilled in the art will understand that the structures andmethods specifically described herein and shown in the accompanyingfigures are non-limiting exemplary embodiments, and that thedescription, disclosure, and figures should be construed merely asexemplary of particular embodiments. It is to be understood, therefore,that the present disclosure is not limited to the precise embodimentsdescribed, and that various other changes and modifications may beeffected by one skilled in the art without departing from the scope orspirit of the disclosure. Additionally, the elements and features shownor described in connection with certain embodiments may be combined withthe elements and features of certain other embodiments without departingfrom the scope of the present disclosure, and that such modificationsand variations are also included within the scope of the presentdisclosure. Accordingly, the subject matter of the present disclosure isnot limited by what has been particularly shown and described.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of particular embodiments. Those skilled in the artwill envision other modifications within the scope and spirit of theclaims appended hereto.

What is claimed is:
 1. An electrosurgical forceps, comprising: a firstshaft member; a second shaft member pivotably coupled to the first shaftmember; a first jaw member secured to and extending distally from thefirst shaft member; a second jaw member secured to and extendingdistally from the second shaft member, the first jaw member including: ajaw frame; an insulative spacer disposed on the jaw frame and defining alongitudinally-extending channel; and a tissue-contacting plate disposedon the insulative spacer; and a knife selectively translatable throughthe first shaft member from a retracted position to an extended positionin which the knife extends at least partially between the first andsecond jaw members, the knife including a distal edge having a sharp,upper segment and a dull, lower segment depending from the uppersegment, the lower segment configured to abut the insulative spacer whenthe knife is in the extended position.
 2. The electrosurgical forcepsaccording to claim 1, wherein the lower segment of the distal edge ofthe knife protrudes distally beyond the upper segment.
 3. Theelectrosurgical forceps according to claim 1, wherein the upper segmentof the distal edge of the knife extends at an oblique angle relative toa longitudinal axis defined by the knife, and the lower segment isperpendicular relative to the longitudinal axis.
 4. The electrosurgicalforceps according to claim 1, wherein the lower segment of the distaledge of the knife is received in the channel of the insulative spacer,and the upper segment is received in a longitudinally-extending channeldefined by the tissue-contacting plate.
 5. The electrosurgical forcepsaccording to claim 1, wherein the lower segment of the distal edge ofthe knife is configured to abut an inner peripheral surface of theinsulative spacer upon the knife moving to the extended position, theinner peripheral surface of the insulative spacer defining an outerperiphery of the channel.
 6. An electrosurgical forceps, comprising: afirst shaft member having a first inner frame; a second shaft memberpivotably coupled to the first shaft member; a first jaw member securedto and extending distally from the first shaft member; a second jawmember secured to and extending distally from the second shaft member; aknife selectively translatable through the first shaft member from aretracted position to an extended position in which the knife extends atleast partially between the first and second jaw members; and anelongate shell attached to a lateral side of the first inner frame anddefining a longitudinally-extending passageway configured for slidablereceipt of the knife therethrough.
 7. The electrosurgical forcepsaccording to claim 6, wherein the elongate shell has an inner surfacethat defines the passageway, the inner surface configured to permitmovement of the knife along a longitudinal axis defined by the knife andresist lateral and vertical movement of the knife relative to thelongitudinal axis.
 8. The electrosurgical forceps according to claim 6,wherein the elongate shell is fabricated from plastic.
 9. Theelectrosurgical forceps according to claim 6, wherein the knife has ablade stop protruding outwardly therefrom configured to abut a proximaledge of the elongate shell when the knife moves to the extended positionto prevent further distal movement of the knife along the passageway.10. The electrosurgical forceps according to claim 6, wherein theelongate shell has a connection tab extending laterally therefrom, theconnection tab configured to engage in a correspondingly shaped aperturedefined in the lateral side of the first inner frame.
 11. Theelectrosurgical forceps according to claim 6, wherein the elongate shellhas a rectangular shape.